Installation of concrete containing railroad ties inflated in situ

ABSTRACT

An inflatable railroad tie includes an elongated, inflatable porous housing which first is inserted in a track bed transversely beneath the rails and longitudinally between the existing deteriorated wooden ties in deflated or collapsed condition, and then is inflated in situ into load bearing relationship with the rails by injecting a concrete forming mixture which upon setting produces a hardened concrete mass filling the housing and supporting the rails, such mass being prestressed by an embedded reinforcing rod extending through and fastened to the housing as well as being secured to the rails by embedded anchors.

United States Patent Dlugosz Sept. 23, 1975 INSTALLATION OF CONCRETE 2.538.443 1/1951 DeLvaux 238/91 CONTAINING RAILROAD TIES INFLATED 3.432.098 3/1969 Sato 238/283 IN SITU 3.622.072 11/1971 Matsubara ct al. 238/283 Inventor: Leonard T. Dlugosz, 4 Minden Dr..

Orchard Park, NY. 14218 Filed: Mar. 27, 1973 Appl. No.: 345,277

Related us. Application Data Continuation-in-part of Ser. No. 198.660. Nov. 15. 1971, abandoned.

.u.s. c1. 238/84 Int. Cl. EOlb 37/00 Field of Search 104/10. 11; 238/83, 84. 238/91, 30, 29, l, 107

References Cited UNITED STATES PATENTS Goldie 104/11 Primary E.\'uminerM. Henson Wood, Jr. Assistant E.\'uminerRichard A. Bertsch ["57 1 ABSTRACT An inflatable railroad tie includes an elongated. inflatable porous housing which first is inserted in a track bed transversely beneath the rails and longitudinally between the existing deteriorated wooden ties in deflated or collapsed condition, and then is inflated in situ into load bearing relationship with the rails by injecting a concrete forming mixture which upon setting produces a hardened concrete mass filling the housing and supporting the rails, such mass being prestressed by an embedded reinforcing rod extending through and fastened to the housing as well as being secured to the rails by embedded anchors.

24 Claims, 13 Drawing Figures US Patent Sept. 23,1975 Sheet 1 of 2 f f V INVENTOR. 8 LEONARD T. DLUGOSZ ATTOANEKf .rlllllllllIIVl US Patent Sept. 23,1975 Sheet 2 of2 3,9U7,201

INSTALLATION OF CONCRETE CONTAINING RAILROAD TIES INFLATED IN SITU This application is a continuation-in-part of my prior copending application Ser. No. 198,660. filed Nov. 15, I971. and now abandoned.

BACKGROUND OF THE INVENTION 1. Field of the Invention This invention relates to improvements in railroad tie installations. and more particularly to a new and improved inflatable railroad tie adapted to be inserted in a railroad track bed beneath the rails and between the existing ties and inflated with concrete in situ; a new and improved inflated concrete containingrailroad tie which is so inserted and inflated in situ; a new and improved installation of such inflated concrete containing railroad tie. and a new and improved method of installing such inflated concrete containing railroad tie.

2. Prior Art In the railroad industry roday. a serious problem exists in the widespread deterioration of roadbeds; primarily caused by rotting of the older wooden railroad ties. This situation is not only hazardous to high speed travel. as can be attained by modern trains, but also often results in derailment of freight cars and extensive loss of cargo. The problem is further complicated by a shortage in supply of the appropriate wood for making the standard wooden ties, and the long delays involved in obtaining such replacement ties.

One proposed alternative is to employ precast concrete replacement ties. but the use thereof is tremendously expensive because of the great weight of such precast concrete ties and the expensive equipment and labor costs involved in installation thereof. Another proposed alternative is to cast in situ integral concrete sleepers and cross ties, as disclosed in US. Pat. No. 1,109,267. However. this invention is not really applicable to worn out individual tie replacement or reinforcement. because it requires the preassembly of the rails and a supporting reinforcing rod and channel network. as well as the use of removable forms to construct a complete railroad bed and rail support. Obviously. the use of such patented system also would be tremendously expensive. particularly when considering the labor and material costs involved in building or rebuilding the railroad bed and rail supports.

SUMMARY OF THE INVENTION Accordingly. it is a primary object of the present invention to provide a new and improved inflatable railroad tie. the elongated inflatable housing of which readily can be inserted in the track bed beneath the rails and between the existing deteriorated wooden ties in deflated or collapsed condition and then readily inflated in situ into load bearing relationship with the rails by filling such housing with a concrete forming mixture which upon hardening will form a concrete mass adequately supporting the rails, all at substantially less cost than that involved in removal and replacement of the deteriorated wooden ties either by newer wooden ties or precast concrete ties, as well as that involved in rebuilding the complete railroad bed and rail support.

Another primary object is to provide a new and improved inflated concrete containing railroad tie so inserted and inflated in situ and including an elongated reinforcing rod embedded in the concrete mass and fastener means engaging the outer ends of the housing and rod. placing the rod in tension and the mass in compression to properly prestress the tie and enhance its load bearing characteristic.

A further primary object is to provide a new and improved installation of such inflated concrete containing railroad tie wherein the latter readily is secured to the rails by anchor means embedded in the concrete mass either in the form of spikes driven in place prior to setting of the concrete forming mixture or in the form of preinstalled eyebolts connected to the reinforcing rod.

Still another primary object is to provide a new and improved method of installing such inflated concrete containing railroad tie including inserting the elongated inflatable housing into the roadroad track bed transversely beneath the rails and longitudinally between the existing ties. and inflating such housing in situ by injecting therein a concrete forming mixture until the housing is fully inflated into load bearing relationship with the rails. such concrete forming mixture being injected either as a premixed wet slurry or in a dry state simultaneously with water injected separately and/or sprayed through the housing to form a wet slurry in situ.

Additionai objects and advantages of the invention will become evident upon consideration of the following detailed description and accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a partial perspective view of a railroad track bed. rails. and existing ties. with part of the bed removed to receive the inventive inflatable tie.

FIG. 2 is a view similar to FIG. 1, but following insertion and during inflation of the inventive tie in situ.

FIG. 3 is a view similar to FIG. 2, but after the inventive tie has been completely installed and the bed has been refilled around the installation.

FIG. 4 is an enlarged broken section taken on line 4-4 of FIG. 2.

FIG. 5 is an enlarged broken section taken on line 55 of FIG. 3.

FIG. 6 is a fragmentary section similar to FIG. 5, but showing an alternate fill tube location in the inventive tie.

FIG. 7 is a fragmentary reduced section similar to FIG. 5, but showing modified anchoring spikes.

FIG. 8 is a partial perspective view similar to FIG. 2, but illustrating a modified inventive tie following insertion and during inflation in situ.

FIG. 9 is a view similar to FIG. 8, but after the modified inventive tie has been completely installed and the bed has been refilled around the installation.

FIG. 10 is an enlarged broken section taken on line l0I0 of FIG. 8.

FIG. 11 is an enlarged broken section taken on line llll of FIG. 9.

FIG. 12 is a section taken on line I2l2 of FIG. 1 1.

FIG. 13 is a fragmentary section similar to FIG. 11, but showing an alternate fill tube location in the modified inventive tie.

DESCRIPTION OF THE PREFERRED EMBODIMENTS FIGS. 1-7

Structure of Installation Referring first to FIG. 1, a railroad track bed is generally indicated at B with part of the bed forming fill, slag or aggregate being removed to form a shallow excavation E exposing a pair of existing conventional wooden ties T. one or both of which is deteriorated. beneath the two rails R. the lower flanges F of which are secured to the tics by the usual spikes S. the well known fish plates" between the rails and ties being omitted for simplicity.

I Turning to FIGS. 2-5, a preferred embodiment of the inventive inflatable tie is generally indicated at 10. with FIGS. 2 and 4 showing the inventive tie after insertion but-during inflation. while FIGS. 3 and 5 illustrate the same following inflation in situ. Inventive tie 10 includcs an elongated inflatable housing I2 which preferably is of cylindrical shape and circular cross-section. but obviously could be of any other suitable shape and cross-section. such as rectangular. like wooden ties T. Preferably. entire housing I2 is formed of porous woven fabric and includes an elongated tubular casing portion 14 preferably made of burlap. and a cap portion 16 preferably made of canvas and closing each open end of the casing portion, with the cap portions being secured in place preferably by stitching 18.

The terms woven fabric" are employed herein to include the use of natural and/or synthetic fibers. as well as to include extruded or spun mesh type fabrics. such as polypropylene plastic filaments wherein the fill and warp filaments are arranged in overlying bonded relationship as opposed to the usual interlaced relationship. Typical of such mesh fabric would be that sold by E. I. DuPont de Nemours & Co. (Inc.) as plastic netting under the trademark Vexar. The weave. at least in casing portion 14, must be open enough to permit migration of the concrete forming mixture through such casing portion as shown in FIG. 5, for a purpose to be described below. and preferably also through cap portions 16. However, the latter. while preferably formed of porous woven fabric. could be formed of imporous woven fabric or other material. if desired.

Casing portion 14 also is provided. preferably in its upper side. with at least one inlet port in the form of a Central upstanding fill tube 20 extending outwardly through and secured to the casing portion by any suitable means such as a crimped washer 22 or the like clamping the casing against the lower outstanding flange portion 24 of tube 20. Each cap portion 16 also is provided with means forming at least one opening and preferably in the form of a hollow grommet 26 which suitably is clinched or crimped in place. preferably below the central longitudinal axis of housing 12 for a purpose to be described below. Alternatively. one or both cap portions 16 could be provided in its upper side with fill tube 20 and washer 22. in place of or in addition to casing I2, as shown in FIG. 6.

As best shown in FIG. 5. inventive tie I is completed by a concrete mass 28 which is hardened or set from a concrete forming mixture injected through fill tube 20 to inflate housing 12 into the illustrated load bearing relationship with rails R. and by at least one elongated reinforcing rod 30 inserted through grommets 26 and casing 14 and embedded in mass 28 preferably during such injection. although rod 30 could be prcinstalled. if desired. Rod 30 has an integral head 32 at one end and is threaded at its other end 34 for engagement by a nut fastener 36. Thus. upon tightening of nut 36 against the adjacent grommet 26, it draws head 32 against the left grommet 26 to place rod 30 in tension and the lower portion of mass 28 in compression for proper prestrcssing of tie It) to enhance its load bearing characteristic.

The installation of tie I0 is completed by anchors in the form of spikes S (FIG. or S (FIG. 7) which are driven into concrete mass 28 before setting thereof. Such spikes may be provided with preformed head portions or they may be peened or bent over lower rail flanges F following setting. in either event to secure the rails R and tie together. Although not shown. as noted above. the usual fish plates could be placed between the rails and tie 10 with the spikes passing therethrough. if so desired.

As shown in FIG. 7, the modified spikes S" are longer and curved at their lower ends. Hence. when driven into place. their lower ends hook beneath rod 30 to further enhance their embedment into concrete mass 28 and the securement between the tie and rails.

Method of Installation Returning to FIG. 1. bed B readily is prepared for installation of tie 10 by removing sufficient aggregate or fill to produce excavation E. thereby exposing wooden ties T and the space therebetwcen. Housing I2 then is inserted in collapsed or deflated condition transversely beneath rails R and longitudinally between ties T. there being no need to remove or replace the latter.

Next. tie 10 is inflated in situ by injecting a concrete mixture through one or more flll tubes (FIG. 4 or FIG. 6) until housing 12 is filled and inflated into the desired load bearing relationship with rails R (FIG. 5 This Concrete mixture may be fluidized in a number of ways. For instance. the mixture may be injected as a premixed wet slurry through the lill tube (s) or a dry mixture of sand. cement and aggregate may be injected from one pipe or hose (not shown) while simultaneously water is injected from another hose (not shown). and/or water may be sprayed through porous housing 12. to forma slurry in situ. In each instance. the proportions of sand. cement. aggregate and water are adjusted as desired. to produce concrete". this term. as employed herein. being construed broadly to include not only conventional concrete forming mixtures incorporating heavy aggregate such as stone or gravel. but also those containing light aggregate such as vermiculite or pearlite. Whatever inflation procedure is employed. it is but a simple matter to mount the readily available economical equipment and tie forming materials on a flat car or the like which readily may be moved along the track as needed. by any suitable prime mover. such as a yard locomotive or the like.

Either before. or during such inflation. such as when the housing is about half full. rod is inserted longitudinally through grommets 26 and housing 12. followed by the aforesaid tightening of nut 36 so that upon setting or hardening ofconcretc mass 28 the lower portion thereof is placed under compression and the rod in tension for properly prcstressing the tie. Also. following such inflation. and prior to setting of mass 28. anchors in the form of spikes S (FIG. 5) or S" (FIG. 7) are driven through casing 14 into the mass to secure the tie and rails together. When preformed. their heads automatically are engaged over the lower rail flanges F by such driving. However. when such heads are not preformed. they preferably are not peened over rail flanges F until after hardening'occurs. say after about 24 hours or so of air drying time.

As shown in FIGS. 3 and 5, the weight of the work train (not shown) passing over the rails, together with the driving of the spikes S or S", particularly when their heads are preformed, allow the same to properly seat themselves in the top of tie 10, in addition to causing the bottom of the tie to assume the contour of the supporting ground, as shown in FIGS. 5 and 7. Also the process of oozing some of the concrete forming matrix or mixture into the slag or stone ballast of bed B beneath and at the ends of tie 10, as shown at 28a in FIGS. 5 and 7, assures a good bond or anchor between the tie and bed.

The final step is to replace the road bed fill or aggregate around the installed tie 10, as shown in FIG. 3, with the inventive tie providing the proper support for the rails, instead of the adjacent deteriorated wooden ties T.

FIGS. 8-13 Structure of Installation Inasmuch as the railroad track bed remains substantially the same as shown in FIG. 1, neither the illustration nor the description of this Figure will be repeated, it being sufficient to note that the same or similar parts are designated by the same numerals followed by a prime in considering FIGS. 8-13, and with different parts being given different numerals.

Turning now to FIGS. 8-13, another preferred embodiment of the inventive inflatable tie is generally indicated at 10, with FIGS. 8 and 10 showing the inventive tie after insertion but during inflation, while FIGS. 9 and 11 illustrate the same following inflation in situ. Inventive tie 10' includes an elongated inflatable housing 12' which preferably is of cylindrical shape and circular cross-section, but obviously could be of any other suitable shape and cross-section, such as rectangular, like wooden ties T. Preferbly entire housing 12 is formed of porous woven fabric and includes an elongated tubular casing portion 14' preferably made of burlap, and a cap portion 16 preferably made of canvas and closing each open end of the casing portion, with the cap portions being secured in place preferably by stitching 18'. The definition of the terms woven fabric as well as the descriptions of the weave and cap portion structure with reference to FIGS. 1-7 are equally applicable to the present embodiment.

Casing portion 14 also is provided, preferably in its upper side, with at least one inlet port in the form of a central upstanding fill tube 20' extending outwardly through and secured to the casing portion by any suitable means sueh as a crimped washer 22' or the-like clamping the casing against the lower outstanding flange portion 24' of tube 20. Each cap portion 16 also is provided with means forming at least one opening and preferably in the form ofa hollow grommet 26 which suitably is clinched or crimped in place, preferably below the central longitudinal axis of housing 12 for a purpose to be described below. In addition, each cap portion is provided, preferably on its outer side, with a reinforcing end plate 26, each grommet 26' being of sufficient axial length to accomodate such end plate, which adds stabilizing rigidity to each cap portion 16. Alternatively, one or both cap portions 16 could be provided in its upper side with fill tube 20 and washer 22', in place of or in addition to casing 12, as shown in FIG. 13.

As best see'n'in FIG. 11, inventive tie 10 is completed by a concrete mass 28 which is hardened or set from a concrete forming mixture injected through fill tube 20 to inflate housing 12 into the illustrated load bearing relationship with rails R, and at least one elongated reinforcing rod 30 extending through grommets 26 and casing 14 and embedded in mass 28' during such injection, together with two pairs of eyebolts 38 forming part of the anchoring structure described below. Rod 30' is threaded at each end 34' for engagement by a nut fastener 36'. Thus, upon tightening of nuts 36 against the adjacent grommets 26', rod 30 is placed in tension and the lower portion of mass 28' is placed in compression for proper prestressing of tie 10' to enhance its load bearing characteristic.

In addition, eyebolts 38 have their eyes 40 slidably surrounding rod 30' and extend laterally outwardly and upwardly therefrom and through casing 10 to expose their threaded outer ends 42. As will be evident, rod 30' and eyebolts 42 are preinstalled in housing 12 during assembly of casingportion l4 and cap portions 16. i

The installation and anchoring of tie 10' is completed by nuts 44, washers 46, rail clips 48, tie or fish plates 50, and an underlying insulation pad 52, of glass fibers or the like, when conductivity may be a problemv The eyebolts extend upwardly through openings in casing portion 14' pads 52 and fish plates 50 underlying rails R, as well as through openings in clips 48 which, upon tightening of nuts 44 and washers 46, are clamped or engaged over lower rail flanges F to secure the tie and rails together, with eyebolts 38 being placed in tension and locked to rod 30' for enhancing such securement.

Method of Installation Returning to FIG. 8, bed B readily is prepared in the same manner as described above with reference to FIG. 1. Housing 12 with the preinstalled rod 30 and eyebolts 38, then is inserted in collapsed or deflated condition transversely beneath rails R and longitudinally between ties T, there being no need to remove or replace the latter, Of course, care is taken to see that each pair of eyebolts 38 properly straddle the appropriate rail R.

Next, tie 10 is inflated in situ by injecting a concrete forming mixture through one or more fill tubes 20 (FIG. 10 or FIG. 13) until housing 12' is filled and inflated into the desired load bearing relationship with rails R (FIG. 11). This concrete mixture may be fluidized, injected and proportioned to produce concrete, all as described and defined in detail above with reference to FIG. 5. However,.prior to and/or during inflation, pads 52 and plates 50 are properly mounted on eyebolts 38 and beneath rails R in any suitable manner. During and/or upon completion of such inflation, rail clips 48, washers 46 and nuts 44 are suitably installed, with the latter being tightened upon completion of such inflation. This tightening, together with the weight of the work train (not shown) passing over the rails, allow plates 50 to properly seat themselves in the top of tie 10, as shown in FIGS. 9 and 11, in addition to causing the bottom of the tie to assume the contour of the supporting ground, as shown in FIGS. 8 and 12. Also,'the process of oozing some of the concrete forming matrix or mixture into the slag or stone ballast of bed'B beneath and at the ends of tie 10', as shown at 28a in FIGS. 11 and 12, assures a good bond or anchor between the tie and bed just as noted above for the embodiment of FIGS. 1-7.

Thus, upon setting or hardening of concrete mass 28', the lower portion thereof is placed under compression and rod 30' in tension for proper prestressing oftie 10'. In addition. eyebolts 38 are likewise placed in tension upon tightening of nuts 44 to enhance the securement between the rails and tie, and if necessary, nuts 44 can be tightened further following such setting.

The final step is to replace the road bed fill or aggregate around the installed tie 10', as shown in FIG. 9, with the inventive tie providing the proper support for the rails, instead of the adjacent deteriorated wooden ties R.

It now is seen how the invention accomplishes its various objects, and numerous advantages inherent in the invention likewise'are evident. For example, both the construction and the installation of the invention ties are simple. effective, efficient and economical, there being no necessity for removing or replacing the deteriorated wooden ties. In addition, even when the inventive ties deteriorate. it isnt necessary to bodily remove them either, because the concrete mass readily may be crushed and reused as aggregate in the road bed.

While the invention has been described and illustrated herein by reference to specific preferred embodiments thereof, this is to be considered as illustrative of rather than as limiting the scope of the invention, which is to be determined by the appended claims.

What is claimed is:

1. An inflated concrete containing railroad tie which is inserted in a railroad track bed beneath the rails and between the existing ties, and inflated in situ, wherein the improvement comprises: an' elongated inflated housing including a hollow tubular casing portion formed of porous woven fabric, a cap portion closing each end of said casing portion, and an inlet port in one of said cap and easing portions, and a hardened concrete mass filling said housing following injection of a concrete forming mixture through said inlet port into said housing.

2. The inflated tie of claim 1 wherein each of said cap portions is provided with means forming an opening, and including an elongated reinforcing rod embedded in said concrete mass following insertion thereof longitudinally through said casing portion and openings, and rod fastener means engaging said means and the outer ends of said rod, placing said rod in tension and said concrete mass in compression.

3. The inflated tie of claim 2 wherein said opening forming means is located in each of said cap portions below the central longitudinal axis of said casing por tion, and said rod fastener means place the lower portion of said concrete mass in compression.

4. The inflated tie of claim 1 wherein said cap portions also are formed of porous woven fabric.

5. The inflated tie of claim 1 wherein said inlet port is in the form of a fill tube extending outwardly through and secured to the upper side of said one of said cap and easing portions.

6. The inflated tie of claim 1 wherein said housing is formed of porous woven fabric, with said casing portion being formed of burlap and said cap portions being formed of canvas and secured to said casing portion by stitching.

7. The inflated tie of claim 1 including a preinstalled elongated reinforcing rod embedded in said concrete mass following insertion thereof longitudinall through said casing portion and said cap portions, rod fastener means engaging said cap portions and the outer ends of said rod, placing said rod in tension and said concrete mass in compression, and anchor means in the form of preinstalled eyebolts embedded in said concrete mass following said insertion, surrounding said reinforcing rod and extending laterally therefrom and through said casing portion for attachment to said rails.

8. An installation of an inflated concrete containing railroad tie inserted in a railroad track bed beneath the rails and between the existing ties and inflated in situ. wherein theimprovement comprises: an elongated inflatable housing inserted into said bed transversely between said rails and longitudinally between said existing ties and including a hollow tubular casing portion formed of porous woven fabric, a cap portion closing each end of said casing portion, and an inlet port in one of said casing and cap portions, and a hardened concrete mass filling and inflating said housing into load bearing relationship with said rails following injection of a concrete forming mixture through said inlet port into said housing.

9. The installation of claim 8 wherein said rails have lower flanges each of said cap portions is provided with means forming an opening, and including an elongated reinforcing rod embedded in said concrete mass following insertion thereof longitudinallythrough said casing portion and openings, rod fastener meansengaging said means and the outer ends of said rod, placing said rod in tension and said concrete mass in compression, and anchor means extending laterally through said casing portion, embedded in said concrete mass and enaged over said lower rail flanges to secure said tie and rails together.

10. The installation of claim 9 wherein said opening forming means is located in each of said cap portions below the central longitudinal axis of said casing portion, and said rod fastener means place the lower portion of said concrete mass in compression.

11. The installation of claim 10 wherein said anchor means are in the form of spikes driven through said casing portion and into said concrete forming mixture prior to setting thereof.

12. The installation of claim 11 wherein said spikes are provided with curved lower ends hooked under said reinforcing rod.

13. The installation of claim 8 wherein said cap portions also are formed of porous woven fabric.

14. The installation of claim 8 wherein said inlet port is in the form ofa fill tube extending outwardly through and secured to the upper side of said one of said casing and cap portions.

15. The installation of claim 8 wherein said housing is formed of porous woven fabric, with said casing portion being formed of burlap and said cap portions being formed of canvas and secured to said casing portion by stitching.

16. The installation of claim 8 including a preinstalled elongated rcinforcing rod embedded in said concrete mass following insertion thereof longitudinally through said casing portion and cap portions, rod fastener means engaging said cap portions and the outer ends of said rods, placing said rod in tension and said concrete mass in compression, and anchor means including preinstalled eyebolts embedded in said concrete mass following said insertion, surrounding said reinforcing rod and extending laterally therefrom and through said casing portion for attachment to said rails, and rail fastener means engaging said eyebolts and rails and placing said eyebolts in tension.

17. A method of installing an inflated concrete containing railroad tie in a railroad track bed beneath the rails and between the existing ties, wherein the improvement comprises: inserting an elongated inflatable housing into said bed transversely beneath the rails and longitudinally between the existing ties, said inflatable housing including a hollow tubular casing portion formed of porous woven fabric, a cap portion closing each end of said casing portion, and an inlet port in one of said casing and cap portions, and inflating said housing in situ by injecting a concrete forming mixture through said inlet port into said housing until filled and inflated into load bearing relationship with said rails upon setting of said mixture to form a hardened concrete mass.

18. The method of claim 17 wherein said rails have lower flanges, each of said cap portions is provided with means forming an opening, and including inserting an elongated reinforcing rod longitudinally through said casing portion and openings, applying rod fastener means engaging said cap portions and the outer ends of said rod, to embed said rod in said concrete mass upon hardening thereof following inflation of said housing, thereby placing said rod in tension and said concrete mass in compression. and applying anchor means extending laterally through said casing portion and engaging said anchor means over said lower rail flanges to embed said anchor means in said concrete mass upon hardening thereof following inflation of said housing.

19. The method of claim l8 wherein opening said forming means is located in each of said cap portions below the central longitudinal axis of said casing portion, and said applying of said rod fastener means places the lower portion of said concrete mass in compression.

20. The method of claim 19 wherein said anchor means are in the form of spikes, and said lower flanges are secured to said tie by driving said spikes laterally through said casing portion into said concrete forming mixture prior to setting thereof and by engaging said spikes over said lower flanges.

21. The method of claim 29 wherein said spikes are provided with curved lower ends which are hooked under said reinforcing rod upon so driving said spikes.

22. The method of claim 17 wherein said concrete forming mixture is injected as a premixed wet slurry, followed by air drying until said slurry sets to form said hardened concrete mass.

23. The method of claim 17 wherein said concrete forming mixture is injected in a dry state simultaneously with water injected separately and/or sprayed through said inflatable housing to form a wet slurry in situ, followed by air drying until said slurry sets to form said hardened concrete mass.

24. The method of claim 17 including preinstalling an elongated reinforcing rod by inserting the same longitudinally through said casing portion and cap portions, applying rod fastener means engaging said cap portions and the outer ends of said rod, to embed said rod in said concrete mass upon hardening thereof following inflation of said housing, thereby placing said rod in tension and said concrete mass in compression and applying anchor means by preinstalling eyebolts surrounding said reinforcing rod and extending laterally therefrom and through said casing portion for attachment to said rails, to embed said eyebolts in said concrete mass upon hardening thereof following inflation of said housing, and applying rail fastener means engaging said eyebolts and said rails following said inflation to secure said tie and rails together, thereby placing said eyebolts in tension.

UNITED STATES PATENT OFFICE CERTIFICATE OF CORRECTION PATENT NO. 3,907,201 DATED September 23, 1975 INVENTOR(S) Leonard T. Dlugosz It is certified that error appears in the above-identified patent and that said Letters Patent are hereby corrected as shown below:

Column 6, line 29, before Colman 7, line 14, change Column 8, 11:19 25, before change change Colmtm 9, line 34,

Column 10, line 8,

[SEAL] AIIESI.

RUTH C.

Arresting Officer Signed and Scaled this sixteenth Day Of December 1975 MASON C. MARSHALL DANN Commissioner ufPatents and Trademarks 

1. An inflated concrete containing railroad tie which is inserted in a railroad track bed beneath the rails and between the existing ties, and inflated in situ, wherein the improvement comprises: an elongated inflated housing including a hollow tubular casing portion formed of porous woven fabric, a cap portion closing each end of said casing portion, and an inlet port in one of said cap and casing portions, and a hardened concrete mass filling said housing following injection of a concrete forming mixture through said inlet port into said housing.
 2. The inflated tie of claim 1 wherein each of said cap portions is provided with means forming an opening, and including an elongated reinforcing rod embedded in said concrete mass following insertion thereof longitudinally through said casing portion and openings, and rod fastener means engaging said means and the outer ends of said rod, placing said rod in tension and said concrete mass in compression.
 3. The inflated tie of claim 2 wherein said opening forming means is located in each of said cap portions below the central longitudinal axis of said casing portion, and said rod fastener means place the lower portion of said concrete mass in compression.
 4. The inflated tie of claim 1 wherein said cap portions also are formed of porous woven fabric.
 5. The inflated tie of claim 1 wherein said inlet port is in the form of a fill tube extending outwardly through and secured to the upper side of said one of said cap and casing portions.
 6. The inflated tie of claim 1 wherein said housing is formed of porous woven fabric, with said casing portion being formed of burlap and said cap portions being formed of canvas and secured to said casing portion by stitching.
 7. The inflated tie of claim 1 including a preinstalled elongated reinforcing rod embedded in said concrete mass following insertion thereof longitudinally through said casing portion and said cap portions, rod fastener means engaging said cap portions and the outer ends of said rod, placing said rod in tension and said concrete mass in compression, and anchor means in the form of preinstalled eyebolts embedded in said concrete mass following said insertion, surrounding said reinforcing rod and extending laterally therefrom and through said casing portion for attachment to said rails.
 8. An installation of an inflated concrete containing railroad tie inserted in a railroad track bed beneath the rails and between the existing ties and inflated in situ, wherein the improvement comprises: an elongated inflatable housing inserted into said bed transversely between said rails and longitudinally between said existing ties and including a hollow tubular casing portion formed of porous woven fabric, a cap portion closing each end of said casing portion, and an inlet port in one of said casing and cap portions, and a hardened concrete mass filling and inflating said housing into load bearing relationship with said rails following injection of a concrete forming mixture through said inlet port into said housing.
 9. The installation of claim 8 wherein said rails have lower flanges each of said cap portions is provided with means forming an opening, and including an elongated reinforcing rod embedded in said concrete mass following insertion thereof longitudinally through said casing portion and openings, rod fastener means engaging said means and the outer ends of said rod, placing said rod in tension and said concrete mass in compression, and anchor means extending laterally through said casing portion, embedded in said concrete mass and enaged over said lower rail flanges to secure said tie and rails together.
 10. The installation of claim 9 wherein said opening forming means is located in each of said cap portions below the central longitudinal axis of said casing portion, and said rod fastener means place the lower portion of said concrete mass in compression.
 11. The installation of claim 10 wherein said anchor means are in the form of spikes driven through said casing portion and into said concrete forming mixture prior to setting thereof.
 12. The installation of claim 11 wherein said spikes are provided with curved lower ends hooked under said reinforcing rod.
 13. The installation of claim 8 wherein said cap portions also are formed of porous woven fabric.
 14. The installation of claim 8 wherein said inlet port is in the form of a fill tube extending outwardly through and secured to the upper side of said one of said casing and cap portions.
 15. The installation of claim 8 wherein said housing is formed of porous woven fabric, with said casing portion being formed of burlap and said cap portions being foRmed of canvas and secured to said casing portion by stitching.
 16. The installation of claim 8 including a preinstalled elongated reinforcing rod embedded in said concrete mass following insertion thereof longitudinally through said casing portion and cap portions, rod fastener means engaging said cap portions and the outer ends of said rods, placing said rod in tension and said concrete mass in compression, and anchor means including preinstalled eyebolts embedded in said concrete mass following said insertion, surrounding said reinforcing rod and extending laterally therefrom and through said casing portion for attachment to said rails, and rail fastener means engaging said eyebolts and rails and placing said eyebolts in tension.
 17. A method of installing an inflated concrete containing railroad tie in a railroad track bed beneath the rails and between the existing ties, wherein the improvement comprises: inserting an elongated inflatable housing into said bed transversely beneath the rails and longitudinally between the existing ties, said inflatable housing including a hollow tubular casing portion formed of porous woven fabric, a cap portion closing each end of said casing portion, and an inlet port in one of said casing and cap portions, and inflating said housing in situ by injecting a concrete forming mixture through said inlet port into said housing until filled and inflated into load bearing relationship with said rails upon setting of said mixture to form a hardened concrete mass.
 18. The method of claim 17 wherein said rails have lower flanges, each of said cap portions is provided with means forming an opening, and including inserting an elongated reinforcing rod longitudinally through said casing portion and openings, applying rod fastener means engaging said cap portions and the outer ends of said rod, to embed said rod in said concrete mass upon hardening thereof following inflation of said housing, thereby placing said rod in tension and said concrete mass in compression, and applying anchor means extending laterally through said casing portion and engaging said anchor means over said lower rail flanges to embed said anchor means in said concrete mass upon hardening thereof following inflation of said housing.
 19. The method of claim 18 wherein opening said forming means is located in each of said cap portions below the central longitudinal axis of said casing portion, and said applying of said rod fastener means places the lower portion of said concrete mass in compression.
 20. The method of claim 19 wherein said anchor means are in the form of spikes, and said lower flanges are secured to said tie by driving said spikes laterally through said casing portion into said concrete forming mixture prior to setting thereof and by engaging said spikes over said lower flanges.
 21. The method of claim 29 wherein said spikes are provided with curved lower ends which are hooked under said reinforcing rod upon so driving said spikes.
 22. The method of claim 17 wherein said concrete forming mixture is injected as a premixed wet slurry, followed by air drying until said slurry sets to form said hardened concrete mass.
 23. The method of claim 17 wherein said concrete forming mixture is injected in a dry state simultaneously with water injected separately and/or sprayed through said inflatable housing to form a wet slurry in situ, followed by air drying until said slurry sets to form said hardened concrete mass.
 24. The method of claim 17 including preinstalling an elongated reinforcing rod by inserting the same longitudinally through said casing portion and cap portions, applying rod fastener means engaging said cap portions and the outer ends of said rod, to embed said rod in said concrete mass upon hardening thereof following inflation of said housing, thereby placing said rod in tension and said concrete mass in compression and applying anchor means by preinstalling eyebolts surrounding said reinforcing rod and extending laterally therefrom and thRough said casing portion for attachment to said rails, to embed said eyebolts in said concrete mass upon hardening thereof following inflation of said housing, and applying rail fastener means engaging said eyebolts and said rails following said inflation to secure said tie and rails together, thereby placing said eyebolts in tension. 